Zero to $1000 folders in just over a month?

[Daniel Fairly Knives]

I just lost my shole shop of 15 years and over 5000 knives made in a devastating fire. This will follow my rebuild.

I'm on a tight budget with no shop building.


First thoughts were to join the local Maker Space. It looked awesome with a big mill, cnc router and they had a waterjet! Long story short the waterjet was key to getting started with no band saw available and it was not maintained well enough to really work. I might go back and try to fix it myself but this is not a dependable shop. Shop ruled out!

I went ahead and bought the tooling for folders... one counterbore, one of each bit, some reamers. I get this stuff mostly from Steve Kelly at ticonnector. I spent about $500 on tooling. I found another cheap aircraft counterbore on ebay so I don't trash my nice one on composites, bought some M.A. Ford reamers and end mills on ebay because I found some odd stuff for cheap.

I was going to waterjet then use the mill at maker space... get stuff flat on a surface plate I have at home. No plan on getting blades parallel yet, I knew I needed a surface grinder and a 2x72... (more coming in a couple of posts!, here are some pics)


This was my Colorado shop before I moved into the big shop in TX. I had a Tormach 1100 CNC, Forge Press, Laguna IQ cnc, over 50k more equipment than in this video. I never even filmed it as I set the whole thing up in a family emergency and it has been one thing after another since then.

My friends made a Gofundme link to help out https://gofund.me/76c5480f3

 

[Daniel Fairly Knives]

Here are the last few knives I made

 

[Daniel Fairly Knives]

Back on to the rebuild! I'm currently waiting to hear back on grinder, surface grinder and waterjet quote. if I can get all of this going my next step is to figure out a really small budget cnc router for scales. I'm trying to get away without a bandsaw for a bit but that may be my best option.

If I can get all of the above figured out I might be making inset locks, they are lightweight.like I like, no lockbar to cut and not much Titanium used. Next in line would be liner locks or frame locks... every process has to be thought through with no tools to start.

I bought a little vise for the mill, a 5" amazon cheapie that should do the trick I was considering making some fixtures but the vise is fast and easy for now.

I'm hoping to get a hand tapping jig, I was going to try and get away with threaded inserts but it might be asking too much.

I bought some $30 amazon belt pack, I have used them before and they are good enough for now. I also got every grit of 3M Gator belt as I rely on them to get a good finish. I'm going to try and get a few better 80 grit belts when I can, I usually buy 3M.

I need to get grinding fast!!! Lets hope I can pull this off asap. I hope to have good news on the grinder up next.

 

[woodysone]

I just lost my shole shop of 15 years and over 5000 knives made in a devastating fire. This will follow my rebuild.

I'm on a tight budget with no shop building.


First thoughts were to join the local Maker Space. It looked awesome with a big mill, cnc router and they had a waterjet! Long story short the waterjet was key to getting started with no band saw available and it was not maintained well enough to really work. I might go back and try to fix it myself but this is not a dependable shop. Shop ruled out!

I went ahead and bought the tooling for folders... one counterbore, one of each bit, some reamers. I get this stuff mostly from Steve Kelly at ticonnector. I spent about $500 on tooling. I found another cheap aircraft counterbore on ebay so I don't trash my nice one on composites, bought some M.A. Ford reamers and end mills on ebay because I found some odd stuff for cheap.

I was going to waterjet then use the mill at maker space... get stuff flat on a surface plate I have at home. No plan on getting blades parallel yet, I knew I needed a surface grinder and a 2x72... (more coming in a couple of posts!, here are some pics)


This was my Colorado shop before I moved into the big shop in TX. I had a Tormach 1100 CNC, Forge Press, Laguna IQ cnc, over 50k more equipment than in this video. I never even filmed it as I set the whole thing up in a family emergency and it has been one thing after another since then.

My friends made a Gofundme link to help out https://gofund.me/76c5480f3

View attachment 3151006View attachment 3151007View attachment 3151008View attachment 3151010

Any idea how the fire started? Wishing you all the best my friend!

 

[Daniel Fairly Knives]

Any idea how the fire started? Wishing you all the best my friend!

50 year old romex wiring would be my guess.

 

[Daniel Fairly Knives]

Here's the likely first new folder design. It's a linerlock.

 

[Daniel Fairly Knives]

I hope the title doesn't sound pretentious, it's mostly in attempt to make it interesting... a lofty goal to attempt. It's pretty scary trying to pull this off.

 

[Bill DeShivs]

Here's the likely first new folder design. It's a linerlock.

View attachment 3152822

You should call that the Phoenix model.

 

[Daniel Fairly Knives]

You should call that the Phoenix model.

That's a good idea! Thanks for the help too, it means a lot.

 

[jfk1110]

Here's the likely first new folder design. It's a linerlock.

View attachment 3152822

What kind of scales??? Nice lines right now..

 

[Ken H>]

Here's the likely first new folder design. It's a linerlock.

View attachment 3152822

I like Phoenix name, and it sure does have nice lines. Looking forward to the final build.

 

[Daniel Fairly Knives]

What kind of scales??? Nice lines right now..

I'm doing a mix of richlite, glass (kinda like G10), carbon fiber and micarta.

 

[Daniel Fairly Knives]

Here's some random work of mine...

I make copper and sterling jewelry too but I lost my torch and supplies, was just getting into Tufa casting.

These are mostly framelocks.

 

[jfk1110]

OD green canvas is. MY end all be all.........Luv dat stuff.....

Looking forward to seeing what develops.........

Thanx for sharing!!

 

[Daniel Fairly Knives]

Still cleaning...

I decided on a 20' cargo container that was by the old shop. it was burnt too but not as badly and is pretty solid. I need to get it insulated/sheathed with some outer walls so it doesn't turn into a oven any day now but I'm happy to have it.

Once the shop is cleaned I have a mill and grinder to set up! I aso got a cnc router to cut scales for inset locks and maybe some inlays.

I'm about to heat treat some 15V Beta Titanium for the new run of knives, it is absolutely wild stuff with 15% Vanadium content.

The new router runs on Easel/open source and I already know the program. I already have some CAD ready to import once the router is set up! I only use it for composites/handle materials.

I'm skipping out on the bandsaw, buffer, tumbler and other stuff for now. Tools will be the Grizzly Mill, Knifedogs Grinder, Surface Grinder Attachment, Anolex CNC Router and that's almost it besides some hand tools like my scribes, 1-2-3 blocks etc. I still have a big surface plate. I'm getting away without any micrometers or calipers and will just use my spindle DRO to figure that out.

 

[SharpBits]

Adapt and overcome!

 

[BogdanS]

Hello my dear friend and brother 'of arms',

Do not fear at all and i am not just saying it but my knifemaking story will tell you that it can be very well done for cheap. On short:

- My workshop is literally 3 honeycomb cells (in total 45 square feet)
- i only have a 500 usd Chinese desktop cnc (also ANOLEX) that i use for composite milling or light engraving) - but very rarely using it
- a 15 years old mini bench drill press (i worked my a..s out to make it precise)
- a 200 usd micro proxxon lathe (for thumb studs, and small parts)
- a 200 usd micro proxxon mill
- a homemade electronically controlled kiln (max 200 usd all in all) - this operation can also be commissioned to specialized third parties more likely as you are in the US where you have lots of pros in this field
- a homemade mini precision belt grinder (max 200 usd)
- i commission all waterjet cutting
- carbide tooling (i know it sounds stupid but the Chinese ones are GREAT for the price and excellent for Titanium) - these cost as low as a 'brand' hss but do the job of a DE made carbide

It is not easy of course because the work multiplies with the lack of machines but with your experience this should not be an issue but i would rather see this as a fresh start and maybe a new way of doing things that will incline you toward small handmade art batches that will give you great satisfaction both professionally and also financially.

Please don't take this as an advice as i don't have the knowledge to tell or teach a master like you anything but i just wanted to encourage you to believe that you can do way more than you can possibly think with very little money

All and only the best, God bless,
Bogdan

 

[Daniel Fairly Knives]

Adapt and overcome!

Check!

 

[Daniel Fairly Knives]

Hello my dear friend and brother 'of arms',

Do not fear at all and i am not just saying it but my knifemaking story will tell you that it can be very well done for cheap. On short:

- My workshop is literally 3 honeycomb cells (in total 45 square feet)
- i only have a 500 usd Chinese desktop cnc (also ANOLEX) that i use for composite milling or light engraving) - but very rarely using it
- a 15 years old mini bench drill press (i worked my a..s out to make it precise)
- a 200 usd micro proxxon lathe (for thumb studs, and small parts)
- a 200 usd micro proxxon mill
- a homemade electronically controlled kiln (max 200 usd all in all) - this operation can also be commissioned to specialized third parties more likely as you are in the US where you have lots of pros in this field
- a homemade mini precision belt grinder (max 200 usd)
- i commission all waterjet cutting
- carbide tooling (i know it sounds stupid but the Chinese ones are GREAT for the price and excellent for Titanium) - these cost as low as a 'brand' hss but do the job of a DE made carbide

It is not easy of course because the work multiplies with the lack of machines but with your experience this should not be an issue but i would rather see this as a fresh start and maybe a new way of doing things that will incline you toward small handmade art batches that will give you great satisfaction both professionally and also financially.

Please don't take this as an advice as i don't have the knowledge to tell or teach a master like you anything but i just wanted to encourage you to believe that you can do way more than you can possibly think with very little money

All and only the best, God bless,
Bogdan

Spot on!

"It is not easy of course because the work multiplies with the lack of machines but with your experience this should not be an issue but i would rather see this as a fresh start and maybe a new way of doing things that will incline you toward small handmade art batches that will give you great satisfaction both professionally and also financially." - I think so too! I was building a midtech company and had recently decided to go back to high end folders.

I had to go check out your work, it is incredible! Awesome lines, design, use of materials, everything.

I'm no master or even very good at this, just really hard headed.

 

[BogdanS]

Spot on!

"It is not easy of course because the work multiplies with the lack of machines but with your experience this should not be an issue but i would rather see this as a fresh start and maybe a new way of doing things that will incline you toward small handmade art batches that will give you great satisfaction both professionally and also financially." - I think so too! I was building a midtech company and had recently decided to go back to high end folders.

I had to go check out your work, it is incredible! Awesome lines, design, use of materials, everything.

I'm no master or even very good at this, just really hard headed.

You are too kind my dear friend, i am not even close to your skill but i greatly appreciate your nice words.

Now the MOST important thing is that you already have 'the brand' - if you sold 1000 usd knives with success this means that you are already a name and that NAME is the only indispensable key to success; you can have 1 million dollars shop with spot on knives but if you are not known equals zero, trust me!

I make knives for 15 long years with thanks good God zero complains and yet i have never ever managed to sell even one knife to hit the 1k price no matter materials, engravings and all - so i am not a 'brand' hence i sell my work for cheap .


Related ti this you are the real deal and i highly appreciate you for managing to grow yourself to be a brand and i sincerely tell you that i am sure you will raise again and this time even higher!

All the best brother, God bless,
Bogdan